Process Management of Adhesive

Bonding in Rail Vehicle Construction

Seite 1 IC RL HC CR EN M3 © Siemens AG 2012

Prologue
Einsatz von Zitaten

„Erwünschte Dinge treten nur

ein, wenn sie geplant wurden;
unerwünschte Dinge stellen sich
von selbst ein.“
Zitat Philip B. Crosby

Seite 2 IC RL HC CR EN M3 © Siemens AG 2012

 DIN 6701
Bonding of rail vehicles and rail vehicle parts

Part 1: Basic terms, basic rules

unpublished preliminary draft
will be dealt with at the end
Part 2: Qualification of the user companies
has been released since 2006
defines the requirements on the manufacturers
basis for company certification
Part 3: Guideline for the construction and verification
published draft since 08.2010
describes the procedure for construction and verification
Part 4: Implementation rules and quality assurance
published draft since 08.2010
describes the procedure for manufacture and quality assurance

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 Guideline bonding supervision

Tasks, responsibilities and

competencies
Personnel qualification
Integration into R&D
Quotation review
Support for construction
Documents concerning adhesive bonding
Construction review
Supplier management
Planning of bonding process
Manufacturing documents
Monitoring of manufacture
Logistics
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Certification

The
Siemens site Krefeld Uerdingen
has been
certified
according to DIN 6701 part 2
since 2008-06-11

for
A1 bondings
in rail vehicle construction

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 Personnel qualification

vKAP development area vKAP factory

qualification EAE qualification EAE

representative of the vKAP

representative of the vKAP
qualification EAE
qualification EAE
KAP interior construction
qualification EAS KAP QM area assembly
qualification EAS
KAP driver‘s cabin
qualification EAS KAP QM area shell construction
qualification EAS
KAP shell construction
qualification EAS
KAP QM area supplier
60% of all component constructors trained in-house
qualification EAS
20% of all assembly staff are EAB‘s
50% of all assembly staff trained in-house KAP process planning
qualification EAS
KAP: bonding supervisor
vKAP: responsible bonding supervisor

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 Classification

Classification of the bonded joints

Depending on the safety-related, functional and
economic significance of the bonded joint, a
division into classes is done on the basis of a
failure sequence analysis
The class determines, for instance,
the effort necessary in development, design
and qualification
Kennzeichnung der
the measures for designing and assuring the Planungsunterlagen
bonding process
The training level of the staff involved in the
overall process

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List with requirements on bonded joints

Input is provided by the following

Breaking down the requirements of
areas:
the total vehicle to the bonded joint
customer
They include the whole product life
specifications process planning
cycle
standards purchase
The list of requirements is the basis
for layout and design of the bonded engineering logistics
joints as well as the selection of the
quality customer service
adhesion system
management

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 Verification

Verification: to show that a bonded joint

meets the requirements in all life cycles
over the planned duration of use.
Possibilities:
verification that load is smaller than load
capacity
testing of component
documented experiences
combination of the three means
Is not limited to the strength test during
operation. Depending on the application,
liability, media resistance, manufacturing
stresses have also to be considered.

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 Stress analysis

Stresses of the overall structure inductive travel sensor

Load cases from rules and standards (DIN

vehicle box side window
EN 12663, UIC 566, DIN EN 15227,…)
Field data (information from real-life
operation)
Calculation
Local stress of the adhesive joint from the
stress of the overall structure
Validation of the calculation
Component tests (pressure cycle test)
Measurement of the relative movement of
bonded components during vehicle gauge block, connected
operation rigidly to window

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 Stress capability

State-of-the-art:
Determination of the reduction factors by
stresses in individual tests
Multiplication of the reduction factors with
nominal value stress capability
Adhesion and cohesion are investigated
separately
Future state-of-the-art: Pull shear specimens for el. thick-layer bonding
Determine stress capability from relevant
stress combinations
Adhesion and cohesion are investigated
separately
Stress < stress capability
fixed with defined strain
Operational strength 30 years!
Specimens for relaxation test

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 Assessment of bids and design

Review system in the design process

Bid Design Review (BDR)
Bid can be implemented
Conceptual Design Review (CDR)
Bonded joints specified
Design Review (DR)
Classes determined
Lists of requirements established
Design Freeze (DF)
Verification tests specified
Design of adhesive seam joint approved
Design Approval (DA)
Verification completed
Planning documents approved

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 Planning documents

3D Model
Complete 3D data. Serves as planning basis
for work scheduling
Mounting document
Documentation of the class
Specification of the joining surfaces
Definition of tolerances for joined parts and
adhesive joint
Description of the form, location and
dimension of the adhesive joint
Specification of the pre-treatment process
Definition of QS measures

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Planning of adhesive process
Manufacturing environment

Light

Cleanliness
Dirt accumulation higher cleaning effort

Existing
Manufacturing process
infrastructure

Place Storage space

Environment
Environment
Temperature or humidity
Temperature or humidity
• increase fixing time and downtime
• reduce skin-forming time or open time
• use accelerated systems

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 Planning of bonding process
Manufacturing facilities

Manufacturing facilities:
Facilities for provision of adhesives and
application
Transport, positioning, fixing devices
Platform technology, special tools
Measuring instruments, measuring devices

must be planned, acquired, qualified, maintained

and in part calibrated

Objective: optimization of
Quality and effectiveness of the manufacturing
process
Ergonomics
Occupational safety

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 Manufacturing documents

Bonding process is an integral part of

the work schedule of the assembly
group
Qualification specifications for
performing parties
Adhesive surface specification
(identifiable for the performing party)
Material list
Reference to safety instructions
General references
Specifications for process assurance
Adhesive process (detailed,
illustrated, tools and devices)
Electronic provision incl. 3D model to
performing staff
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General quality specifications
Q measures depending on component class
A1
- performing EAB
- company-specific operating instruction
- quality stopping point
- checking of ambient conditions
- checking of best-before date
- bonding protocol
- adhesion test monitoring production
A3
- performing party in-house training
- construction specification
- checking of ambient conditions
- checking of best-before date
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A2
- performing EAB
- company-specific operating instruction
- quality reporting point
- checking of ambient conditions
- checking of best-before date
- bonding protocol
- adhesion test monitoring production
small sample size
No class
- construction specification
- checking of ambient conditions
- checking of best-before date
© Siemens AG 2012
 Process documentation

Bonding protocol:
Documentation requirement
Allocation of adhesive materials to the
bonding process (batch number)
Process assurance (check list of important
characteristics, e.g. visual test of the
surfaces)
Recording of the test result of the work
sample during production
Description of measures in the case of
interferences in the process (signed by the
KAP)
Possibly customer specifications

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 Monitoring quality assurance

Depending on the component class, stopping points are allocated to bonding

components in an EDP system. For every production order, a testing order
is generated from this:
Quality stopping point: production reports bonding components to quality
assurance, process monitoring compulsory
Quality reporting point : production reports bonding components to quality
assurance, process monitoring system-supported optional
In the case of process deviations, the bonding supervision must be consulted.
They decide on necessary measures.

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 ue
Epilogue
Einsatz von Zitaten

„Es gibt absolut keinen Grund,

warum ein Produkt oder eine
Dienstleistung Fehler oder Mängel
aufweisen sollte.“
Zitat Philip B. Crosby
© Siemens AG 2011
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